High-protection Egg Carton Cellular Configuration

Abstract

An egg carton, having two rows of cavities of six each, that has the individual cavities separated from each other longitudinally and transversely by a combination of transversely and longitudinally extending walls, the walls having sloping sides and meeting at a point intermediate the depth of the cavities to provide for easy egg removal. In addition to the wall separator members, the cellular bottom portion of the carton is further characterized by having a number of upwardly projecting tips to provide for individual egg separation.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to molded egg carton structures comprising a bottom tray section and a top cover section movably secured thereto. In particular, the bottom tray section is characterized by having a plurality of contoured walls defining egg receiving cavities, open at the top and arranged in two adjacent rows of six each. The egg receiving cavities are separated one from the other by a combination of longitudinally and transversely extending tapered wall members as well as by a plurality of projecting tips. Such a configuration assures (a) easy removal of individual eggs from the carton; and (b) maximum protection of the eggs from breakage when compressive forces are applied during normal handling and shipment of such cartons. In particular, the cellular bottom section offers resistance to compressive forces which may be exerted in either a longitudinal or transverse direction with respect to the bottom cellular section of the carton.

2. Description of the Prior Art

U.S. Pat. No. 3,563,446 discloses an egg carton which has a cellular configuration in the bottom tray portion of the carton characterized by having, in addition to projecting tips to provide for individual egg separation, at least one or more transverse wall sections designed to resist compressive forces which are applied to such a carton in the transverse direction. The carton structures of the present invention, in addition to offering resistance to compressive forces applied in such transverse direction, offer added resistance to compression when applied to the carton in a longitudinal direction, i.e., against the respective ends of the carton.

SUMMARY OF THE INVENTION

The present invention relates to molded egg cartons comprising a bottom tray section and a top cover section movably secured thereto. The bottom tray section is characterized by having a plurality of contoured walls defining egg receiving cavities open at the top and arranged in two adjacent rows of six each. The transversely adjacent cavities in these rows constitute a cavity pair. Transverse walls, longitudinal walls and projecting tips serve to separate the individual eggs and also form a portion of the walls of the individual cavities. The longitudinally extending walls which are located between the rows of cavities comprise both (a) upwardly extending projecting tips which are positioned centrally in said longitudinal rows, these tips being intermediate centrally located cavity pairs; and (b) longitudinally extending wall members located at opposite ends of the tray section, each of these wall members separating at least two adjacent cavity pairs. The egg-separating walls which extend in a transverse direction in the bottom tray member of the egg carton structure of the present invention include continuous wall members which extend transversely across the cellular bottom tray member from the front thereof to the back. These transverse wall members are located centrally in the tray section. Additional transversely oriented wall-separating members are located at opposite ends of the tray and comprise upwardly extending projecting tips located intermediate at least two adjacent cells in the longitudinally extending cell rows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the cellular structure of the egg carton of the present invention.

FIGS. 2 and 3 illustrate a type of locking arrangement which may be employed on the carton structures of the present invention.

FIG. 4 is an illustration of a modified form of the locking arrangement illustrated in FIGS. 2 and 3.

DESCRIPTION OF SPECIFIC EMBODIMENTS

Referring now to the drawings, and particularly to FIG. 1, the egg carton structure of the present invention includes a bottom, or tray section, 10 and a top, or cover section, 30. The tray section 10 is formed of a plurality of contoured walls, the first four of which are numbered 11 to 15, defining egg-receiving cavities 21, 22, 23, 24, the other walls and egg-receiving cavities not being separately numbered and being similar. The egg-receiving cavities are separated from each other by two pairs of longitudinally extending walls seen at 19 and 19', to separate the egg-receiving cavities into two rows of six each. Walls 19' are located at opposite ends of the cellular bottom section and extend longitudinally inwardly from each end of the carton bottom section whereby each wall 19' separates two adjacent cavity pairs at each end of the carton bottom, or tray section, 10. Intermediate longitudinally extending walls 19' and located centrally of tray section 10 are longitudinal walls 19. These walls 19 are brought together as extending tips 29, in the form of a top pinch; from tips 29, sloping sides 28 extend to the spaces between the egg-receiving cavities. The height of tips 29, of walls 19, and the height of the longitudinal end wall members 19' are essentially the same as the depth of the cavities, so that they will be approximately at the same level as the rim of the tray section 10. They may project slightly thereover, or be slightly depressed; preferably they project somewhat, but not more than a quarter inch or so, so that they will still be substantially at the same height as the rim of tray 10.

The egg-receiving cavities in each of the two longitudinally extending rows of cavities are separated from each other by walls 18 and 18'. Walls 18 located at opposite ends of each longitudinally extending cell row may be similar to walls 19 and likewise be brought out to a pinched tip. The sloping sides of walls 18 taper downwardly and merge at a point intermediate longitudinally extending cell walls 19'.

As shown in FIG. 1, cell walls 18' are also employed to support adjacent egg-receiving cavities in each of the two rows of cavities. Walls 18' preferably are located centrally of said tray section 10 and although as illustrated in FIG. 1, three of such transversely extending cell walls are shown, less than three may be employed depending upon the desired strength requirement of the particular carton. Transversely extending continuous wall members 18' have sloping sides 25.

In accordance with another feature of the present invention, cover section 30 may have depression 30' formed therein of sufficient depth and so located that it bears against the top ridge of the centrally located transverse wall 18'. Such an arrangement allows the carton, when in closed position, to resist collapse when compressive forces are applied against the cover section 30 of the carton.

The cover section 30 is secured to the tray section 10 by means of an integral, plastic hinge 32, as well known in the art.

The top cover section 30 is box shaped, and has a cover panel 31 and four side panels 32, 33, 34 and 35, which are flanged and engage the periphery of the tray section 10. The front longitudinal side 32 of the cover section 30, as more clearly illustrated in FIGS. 2 and 3, has a plurality of recesses 41 projecting inwardly from the plane of wall member 32. Recesses 41, in addition to imparting rigidity and strength to wall 32, also act as guidance elements to insure correct carton section alignment when the top and bottom sections are being closed. This is more fully described below.

Although a variety of latching arrangements may be employed to secure the carton structures of the present invention in a closed position. A preferred form of latching arrangement is one comprising at least one aperture or slit, and preferably two, formed in the front wall of the carton and an inwardly projecting detent member immediately below such a slit or aperture, the detent terminating adjacent the lower edge of the carton front wall. The latching arrangement is further characterized by the employment of a locking flap attached to the front edge of the bottom carton cellular section. The flap has at least one recess adapted, when the flap is in an upright position and located inside the front wall of the cover section, to cooperating with the inwardly projecting detent on the front wall of the cover to releasably hold the carton structure in a locked position.

An example of such a locking arrangement which may be employed to latch the carton structure of the present invention, i.e., releasably secure the cover section 30 to the bottom, or tray section 10, is illustrated in FIGS. 2 and 3 of the attached drawings has been found to be particularly suitable for carton structures of the present invention. As illustrated in FIG. 2, a carton locking flap member 42 is hinged to the longitudinal edge of tray section 10. Locking flap member 42 is characterized by having a plurality of recesses 44 projecting inwardly from the plane of locking flap 42. Recesses 44 are adapted to engage with recess elements 41 in the front wall panel 32 when the carton is in a closed position, i.e., when flap member 42 is rotated up and positioned inside and bearing against front wall 32 of cover section 30 as the carton is closed. These mating recesses serve to assist in guiding the locking elements hereinafter discussed into proper alignment and thereby assure positive latching of the carton when it is in a closed position. As illustrated in FIGS. 2 and 3 latching of the carton is affected when, as the carton assumes a closed position with flap 42 inside front wall 32 of the carton cover portion, latching bar 45 located above inwardly projecting recess 46 snaps into latching engagement with aperture 47 located in front wall member 32. It will be noted that the upper edge of inwardly projecting detent member 48, when the carton is in closed and latched position, engages the undersurface of latching bar 45 located above recess 46. Recess 46 is large enough to accommodate inwardly projecting detent 48 when the carton is in a closed and latched position. In order to open the carton the user merely presses inwardly against exposed latching bar 45, thereby disengaging the upper edge of detent 48 from latching bar 45.

As illustrated in FIG. 4 a modified form of the carton locking arrangement, illustrated in FIGS. 2 and 3 may also be employed with the cellular carton structures of the present invention. As shown in FIG. 4, inwardly projecting recess 41', located in front cover wall 32, terminates in an edge 50. Edge 50 lies in substantially the same plane as front cover wall 32. There is essentially no aperture in front cover wall 32, as in the case of the latching arrangement shown in FIGS. 2 and 3. Inwardly projecting detent member 48' cooperates with latching bar 45 (not shown) in the same manner as the carton latching arrangement illustrated in FIGS. 2 and 3 described hereinabove.

Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to, without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such variations and modifications are considered to be within the purview and scope of the appended claim.

Claims

What is claimed is:

1. A molded egg carton structure comprising a bottom tray section and a top cover section movably secured to said bottom tray section, said bottom tray section including a plurality of contoured walls defining egg receiving cavities open at the top and arranged in two adjacent rows of six each, transversely adjacent cavities in said rows constituting a cavity pair, transverse walls and longitudinal walls separating said individual cavities, said longitudinal walls located between said rows of cavities comprising (a) upwardly extending projecting tips positioned centrally of said tray section intermediate centrally located cavity pairs; and (b) longitudinally extending wall members, each of said wall members separating two adjacent cavity pairs, said longitudinally extending wall members being located at opposite ends of said tray section, said longitudinally extending wall members being further characterized by having a continuous longitudinally extending, upper edge said continuous upper edge lying in substantially the same plane as the top edge of said tray section and; said transverse walls comprising (a) at least one continuous wall member extending continuously transversely across said bottom tray section, perpendicular to and intermediate at least two cell pairs; and (b) upwardly extending projecting tips, located centrally, intermediate at least two adjacent cells in said longitudinally extending cell rows.